Bipolar unit for fuel cell provided with porous current collectors

ABSTRACT

The invention describes a bipolar unit consisting of a pair of metal plates at least one of which is corrugated, fixed by continuous and hydraulically impervious connections, and provided on the external surfaces thereof with porous electric current collectors also suitable for the distribution of the gaseous reactants. The collector facing the plate corrugations is interpenetrated therein, thereby achieving a continuous contact. Two bipolar units of the invention and one interposed MEA element are assembled to form an elementary fuel cell with an improved electric current distribution. Furthermore the channels formed between the mutually contacting surfaces of the plate pair by the corrugations of at least one of the plates of each bipolar unit, are crossed by a coolant allowing to optimally adjust the cell operative temperature.

Fuel cells are long known as a direct conversion device of the chemicalenergy of combination of gaseous reactants, more particularly of a fuelsuch as hydrogen and an oxidant such as air, into electrical energy.Fuel cells are therefore not subject to the known limitation of Camot'scycle and are characterised by a remarkably high efficiency incomparison with that of the conventional devices for the production ofelectrical energy in which an intermediate thermal stage is present.

Among the various known types, the ionomer membrane fuel cell (PEMFC,from Proton Exchange Membrane Fuel Cell) has earned a specialconsideration for the capability of responding to quick power demandsand for the simplicity of the required auxiliaries, particularlyappreciated for electric vehicle applications. The PEMFC consists of anelectrochemical unit comprising an ionomer membrane, of theperfluorinated type as known in the art and as commercialised forinstance by DuPont, USA under the trade-mark Nafion® or of thehydrocarbon type based on monomers derived from polymeric structuressuch as polystyrene, polyetheretherketones, polybenzimidazol, on whosefaces are applied two electrodes, anode (negatively charged) and cathode(positively charged), in form of porous films containing suitablecatalysts. The combination of the membrane with the porous electrodicfilms is usually indicated with the acronym CCM (from Catalyst-CoatedMembrane). The external surfaces of the electrodes are in contact intheir turn with conductive porous layers, known as diffusion layers,suited to establish a homogeneous distribution of the gaseous reactantson the catalytic films. The overall element resulting from the CCMassociated with the diffusion layers (known to the experts in the fieldwith the acronym MEA, from Membrane-Electrode Assembly) is insertedbetween two planar conductive structures, directed to ensure both theelectric current uniform distribution and the supply of the reactants tothe diffusion layers: such structures are known in the art as collectorsand, depending on the manufacturing technique, may consist of platesprovided with suitable grooves or projections, for instance as proposedin U.S. Pat. No. 6,274,262, or by layers characterised by high porosity,as claimed in U.S. Pat. No. 5,482,792. The MEA and the relevantcollectors, together with suitable sealing gaskets, are finally enclosedbetween a pair of bipolar plates, consisting of two suitable shapedsheets, impervious to the reactants and endowed with electricalconductivity. According to some types of technology the bipolar platesmay also be integrated with the collectors to form a single object, asdisclosed in the above cited document U.S. Pat. No. 6,274,262. The fueland the oxidant are supplied through suitable openings obtained in thebipolar plates and are respectively distributed to the anode and to thecathode through the collectors and the diffusion layers of the MEAelement. The fuel, for example hydrogen, is oxidised with generation ofprotons and electrons. Protons migrate across the ionomer membrane andparticipate to the reduction reaction of the oxygen of the air withformation of water. The electrons required for the reduction come fromthe anode through the external electrical energy appliance circuit. Themigration of protons requires that the ionomer membrane be maintained ina fully hydrated condition, which may be accomplished either byhumidifying the gaseous reactants before their admission or by directlyinjecting water into each of the stack cells. The conversion efficiencyof the chemical energy of reaction into electrical energy, althoughsubstantially higher than that of the conventional generators, islargely below 100%: the fraction of chemical energy not converted intoelectrical energy is dissipated as thermal energy which has to bewithdrawn by means of a suitable cooling device to maintain the cellinternal temperature typically around 60-100° C. The cooling device ispreferably of the forced air-type for the small power systems and ofdemineralised water or diathermic liquid (hereafter genericallyindicated as coolant) circulation-type for systems of higher power. Inthe latter case the cooling is normally carried out by making thecoolant flow along at least one of the bipolar plates. Since theelectric voltage of a single cell under load is modest, in the order of0.7-0.8 Volts, the high voltages normally required by the appliancesystems are obtained by assembling a multiplicity of single PEMFCsintercalated with the cooling devices in blocks (stacks in thefollowing, as commonly known to the experts in the field).

The given description, although necessarily in brief, demonstrates howcomplex a PEMFC stack structure is and hints at how difficult it is toobtain compact stacks as required in vehicular applications in whichreaching a high power density matters, not only in terms of kW/l butalso of kW/kg: since the volume and weight of the MEA unit is veryreduced, this target is substantially affected by the design and thematerials employed for the production of the bipolar plates andcollectors. A further complication typical of vehicular applications isgiven by the peak power demands to which corresponds a high currentintensity generation: in order to avoid that damages to the catalyticfilm activity take place in these conditions, it is fundamental thatsuch currents be evenly distributed on the surface of MEA units. Theprior art proposes on this regard bipolar plate and collector structureswhich do not allow to manufacture stacks with satisfactory powerdensities, in particular with power densities suitable for use onvehicles and/or to achieve the desired uniformity in currentdistribution.

U.S. Pat. No. 6,132,895 discloses metal bipolar plates with a typicalthickness of 1-2 mm and provided with grooves or both sides obtained bymeans of photolithography, or laser radiation etching or microabrasion.The plates are coupled to intercalated MEA units with the reactantsgases flowing through the grooves. To decrease the overall volume, theresulting stack is free of cooling devices and the operating temperaturecontrol is obtained by feeding air in a strong excess with respect tothe reaction stoichiometry requirement: the generated heat is absorbedby the flowing air and extracted from the stack. The described solutionreduces the volumes but only in part, considering the thicknesses in anycase required to manufacture the bipolar plates, and at any rate at thecost of a strong operative criticality associated with the easy membranedehydration induced by high gas flow-rates: such risk is so high,particularly at high output regimes, that is common practice to employ acoolant for withdrawing the heat generated during operation. Furthermoreonly the apexes of the external grooves are put in contact with thesurfaces of the MEA unit diffusion layers during the assembly of astack. This type of assembly implies a few remarkably serious problems.Firstly, the desired uniformity in the current distribution is notachieved: in fact, the diffusion layer alone is not capable of ensuringsuch an important function in view of the reduced thickness and therelatively modest electrical conductivity. Secondly, the localisedcontact on the apexes of the grooves implies an increase in themechanical solicitation when stacks are tightened, with substantialrisks of damaging delicate components such as the ionomer membranes andthe diffusion layers themselves. Finally it is apparent that the gaseousreactants are subject to stagnation in the contact zones betweendiffusion layers and groove apexes: here the fresh gas supply to thecatalytic films is slowed down by the necessary lateral diffusion, whichis not negligible in view of the lesser porosity generated by the highercompression.

US 2002/0168561 proposes the use of thin metal bipolar plates whereinthe grooves are generated by corrugations obtained by cheaper mechanicalmoulding processes. While this finding solves the cost problemsnegatively affecting U.S. Pat. No. 6,132,895, it certainly does notovercome the problem of current distribution unevenness and of theslowed diffusion in the contact zones of MEA units with the corrugationapexes.

US 2001/0008719 discloses metal plates, respectively cathodic andanodic, provided on both sides with projections obtained by a process ofcontinuous mechanical deep-drawing. The cathodic and anodic plates arerespectively fastened in pairs so as to bring facing projections incontact: an internal space crossed by a suitable coolant duringoperation is thereby defined. The object formed in this way can bedefined for the sake of simplicity as a bipolar unit, the externalprojections whereof are put in contact with the diffusion layers of theMEA units during the assembly of a stack. It is thus evident that thetype of construction, while allowing to obtain good power densities, isnot capable as already discussed to achieve the desired currentdistribution uniformity not to prevent the slowed diffusion in thecontact zones between MEA units and projection apexes.

In EP 1 504 481 there is disclosed the use of smooth cathodic and anodicmetal plates and of separate collectors consisting of highly conductiveporous layers. Similarly to what has been reported in the case of theprevious document, the coupling of the components leads to the formationof a bipolar unit consisting in succession of a first external collector(for instance cathodic collector), a plate, an internal collector(directed to define an internal space for the circulation of a coolant),a plate, a second external collector (for instance anodic collector).When assembling multiplicities of bipolar units and MEAs for producingstacks, both the external and the internal collectors ensure a uniformcontact with the metal plate and MEA unit surfaces: therefore it can besaid that the stacks comprising the above disclosed bipolar units arecharacterised by an improved electric current distribution also in highoutput situations, besides the elimination of mechanical shapingprocedures given the fact that the components are directly available onthe market. Nevertheless, this stack turns out not to be completelysatisfactory under the standpoint of power densities, which seldom reachthe required values in view of the amount of elementary pieces involved.Moreover, since in each bipolar unit are present, during operation, noless than six contact surfaces (respectively MEA-first collector, firstcollector-plate, plate-internal collector, plate-second collector,second collector-MEA), the effective performances may be negativelyaffected with the functioning time by the formation of low-conductivityoxides, as occurs with stainless steels, nickel alloys and titaniumcurrently used for the production of plates and collectors.

The above cited U.S. Pat. No. 6,274,262 proposes a bipolar unitcomprising a cathode plate and an anode plate provided with grooves onthe external surface and a central plate with grooves on both faces: thetightening of the three elements allows creating internal channels forthe passage of a coolant. A multiplicity of bipolar units of this kindis assembled with the required MEA elements intercalated thereto to forma stack in which the gaseous reactants flow during operation in thechannels defined by the grooves present on the external surfaces of thecathodic and anodic plates and by the facing MEA elements.

The sealing of the internal channels requires the surfaces to haveextremely strict planarity tolerances only obtainable by precisionprocedures characterised by production costs not compatible withcommercial applications, especially in the automotive field, and by theneed to resort to sensible thicknesses with a negative consequence onthe achievable power density values. Furthermore the bipolar unit designwith grooves in contact with the MEA units introduces, as seen above,problems of electric current distribution and of slowed diffusion in thecontact zones, especially serious in high output conditions. Finally,the number of contact surfaces introduces the previously discussed riskof performance decay associated with the superficial oxide growth.

US 2005/0170232 proposes a bipolar unit structure equivalent to the oneof the previous document characterised by applying an adhesive film tothe groove apexes: in this way, not only a monolithic object easier tohandle in the stack assembly phase is obtained, but the electricalcontact between MEA and bipolar unit is also stabilised since theadhesive prevents detachments between the groove apexes and the facingMEA element surfaces and protects the contact point from the action ofaggressive agents. This finding allows to maintain performances morestable in time, but it doesn't prove by any means advantageous asregards the problem of electric current distribution unevenness and ofthe slowed diffusion in the contact zones between MEA unit and grooveapexes.

US 2003/0049515 discloses a bipolar unit consisting of cathodic andanodic plates obtained from metal sheets whereon projections areproduced by deep-drawing on both faces, and of a central metal plate:the assembly of the three components allows creating an internal spacefor the passage of a coolant. The use of three plates to form thebipolar unit involves complications in achieving high power densities,and furthermore the point contact between projections and MEA elementsleads back to the above problems of current distribution unevenness,slowed diffusion and possible decay in time of the performancesassociated to the number of interfaces.

U.S. Pat. No. 5,858,567 proposes to overcome the difficulties generatedby the simple mechanical contact between various surfaces by aid of abipolar unit consisting of an assembly of metal leaflets suitablyprovided with grooves on their surfaces and integrated to form amonolithic object by welding under vacuum. To limit the thickness andweight of the bipolar unit as required in order to achieve the target ofhigh power densities, the leaflets are obtained out of thin sheetswhereon the various types of grooves are obtained by photolithographyfollowed by chemical etching. The resulting bipolar unit typically has athickness of 2.5 mm allowing to produce stacks with good power density.Since also in this case the contact is realised between apexes of theexternal grooves and MEA element surfaces, also the bipolar unit of U.S.Pat. No. 5,858,567 remains affected by the problem associated with thecurrent distribution and the slowed diffusion in the contact zones.

In conclusion, the overview of the prior art demonstrates that theconstructive solutions proposed until now are not capable ofsimultaneously solving the two problems of high power densities anduniform electric current distribution, particularly at high outputregime.

Under a first aspect, the present invention has the scope of providing afuel cell bipolar unit overcoming the limitations of the prior art.

Under a second aspect, the present invention has the scope of providinga fuel cell delimited by a pair of bipolar units overcoming thelimitations of the prior art.

These and other objects will be clarified by the following descriptionand by the appended figures, which are not to be intended as limitingthe invention.

The invention consists of a fuel cell bipolar unit delimited by a pairof metal plates, each provided with an internal surface and an externalsurface, whose internal surfaces are maintained in mutual contact bymeans of relevant connections; the plates of the bipolar units are alsoprovided with corrugations and openings suitable for ensuring thecirculation of the gaseous reactants, the relevant products and thecoolant. The bipolar unit of the invention is characterised in that eachof the two external surfaces of the plates is in a uniform andcontinuous electrical contact with a planar, conductive and porouscurrent collector. According to one preferred embodiment of theinvention, the plates are provided with corrugations also in theperipheral zone, external to the cell active area, where the hydraulicsealing is accomplished by the coupling with suitable planar gaskets.

Under a further aspect, the invention consists of a fuel cell comprisinga pair of said bipolar units with an interposed MEA assembly; the cellis characterised by a uniform electrical contact between the diffusionlayer surfaces of the MEA assembly and the surfaces of the porouscurrent collectors in contact with the plate external surfaces.

According to one preferred embodiment of the invention, only one of themetal plates delimiting the bipolar units is provided with corrugations.

According to another preferred embodiment of the invention, thecorrugations of one or both plates of the bipolar unit are obtained bypressure moulding of planar sheets; the thickness of the corrugations ispreferably comprised between 0.1 and 0.5 mm.

In one preferred embodiment, the connections between the respectiveinternal surfaces of the plates of the bipolar unit define channels forthe passage of the coolant. Such connections are optionally continuousmaking the channels and the peripheries of the openings for thecirculation of the gaseous reactants, the products and the coolanthydraulically impervious; the continuous connections may for instance beobtained by laser or braze welding.

In one preferred embodiment, the porous collector in contact with theexternal surfaces of the plates delimiting the bipolar unit isinterpenetrated with the corrugations of the facing plate, andoptionally secured by laser welding or by means of an optionallyconductive adhesive.

The interpenetrated collector may be obtained by pressing of the porousplanar collector on the corrugated plate facing surface, or by pressuremoulding of the planar sheet of the facing plate and of the planarcollector with simultaneous formation of the plate corrugations andinterpenetration of the collector with the corrugations.

The porous collectors of the bipolar unit are materials known in thefield of fuel cell construction, and may be selected from the group offoams, cloths, meshes and expanded sheets, sintered powders, taken assingle pieces or variously overlaid and combined; the constituentmaterial of collectors and plates is preferably selected from the groupof stainless steels, nickel alloys and titanium.

In one preferred embodiment of the invention, the planar sheet of thebipolar unit plates has a thickness comprised between 0.05 and 0.2 mm,while the foam of the porous collector has an initial thicknesscomprised between 0.5 and 5 mm and is compressed up to a final thicknesscomprised between 0.2 and 0.5 mm with pores having an average diameterof 0.2 to 0.5 mm.

The plates and the porous collectors are optionally provided with anelectrically conductive corrosion-protective film selected from thegroup comprising the platinum group metals or oxides thereof optionallyadded with adhesion promoters selected from the group of niobium,titanium, tantalum and zirconium; in one preferred embodiment, theprotective film comprises ruthenium or ruthenium oxide.

In one preferred embodiment of the invention, the protective film has athickness comprised between 0.1 and 1 micrometres and its porosity isnot higher than 50%.

The finding of the present invention will be described making referenceto the following figures, which have a merely exemplifying purpose:

FIG. 1: front-view of an embodiment of the first plate delimiting thebipolar unit of the invention, provided with corrugations.

FIG. 2: front-view of an embodiment of the second plate delimiting thebipolar unit of the invention, free of corrugations.

FIG. 3: view of the lateral section along the line X-X of the firstplate provided with corrugations of FIG. 1.

FIG. 4 a: side-view of the abutment of the first corrugated plate ofFIG. 1 along the line X-X to the second smooth plate of FIG. 2 along theline Y-Y.

FIG. 4 b: side-view of the assembly formed by the abutment of FIG. 4 awith indication of the fixing points obtained by laser or braze welding.

FIG. 5: front-view from the smooth plate side of the assembly of FIG. 4b with the hatched lines indicating the track of the laser or brazewelding ensuring the sealing of the openings and of the internalchannels (not visible) for the passage of the gaseous reactants and thecoolant.

FIG. 6: side-view of the complete bipolar unit wherein the assembly ofFIG. 4 b is coupled to conductive and porous current collectors, withthe corrugations of the first plate interpenetrated in the facingcollector.

FIG. 7: side-view of a fuel cell comprising two bipolar units of thetype illustrated in FIG. 6 with an interposed MEA element.

As it will be made clear by the present description, the bipolar unit ofthe invention suitable for being used in conjunction with MEA elementsfor the construction of fuel cells, in particular membrane fuel cells,comprises the assembly consisting of a first corrugated plate and asecond smooth or optionally also corrugated plate, said plates beingprovided with external and internal surfaces and with connectionsbetween the relevant facing internal surfaces, and a pair of porouscollectors, wherein the corrugations of the first plate areinterpenetrated in the relative collector. The plates and the collectorsare produced with electrically conductive materials inert to thecorrosive action of the process fluids.

The first corrugated plate delimiting the bipolar unit of the inventionis represented in FIG. 1, wherein (1) indicates the internal face of theplate to be contacted by an appropriate second plate, (2) the openingfor the admission of the coolant, (3) the channels for the passage ofthe coolant corresponding to corrugations obtained by pressure mouldingof a planar sheet (5), whose non-moulded portion (4) forms the wall ofthe channels, (6) and (7) the openings for the two gaseous reactants(oxidant and fuel), (8) and (10) the distributing channels of the firstand of the second gaseous reactant respectively, also corresponding tocorrugations obtained by pressure moulding of the planar sheet, (9)holes suitable for distributing the first of the gaseous reactants tothe relevant first porous collector in contact with the plate externalface (not visible) with the hatched line (12) defining the outlinethereof, (11) the holes required for housing the compression tie-rodsneeded for assembling multiplicities of individual cells.

The sheet is usually a stainless steel or nickel alloy or titanium sheetand has a thickness comprised between 0.05 and 0.2 mm, while thecorrugations obtained by moulding have a height falling in the range of0.1 to 0.5 mm.

FIG. 2 represents a front-view of the second plate delimiting thebipolar unit of invention in the smooth plate version, obtained from theplanar sheet by simple punching and also characterised by an internalface (not visible) directed to contact the internal face of the firstplate and by an external face (13), with the holes (14) suitable fordistributing the second of the gaseous reactants in the relevant secondporous collector in contact with said external face. The other detailsin common with the first plate are indicated with the same referencenumerals.

The structure of the first plate is more easily understood by aid ofFIG. 3 which reproduces the side-view along the line X-X of FIG. 1: thehatched arrows indicate the direction of the punches in the mouldingprocess of the corrugations labelled with the numeral (4) alsoidentifying the corresponding channels. The details in common with FIG.1 are indicated with the same reference numerals.

FIG. 4 a shows, in a side-view along the lines X-X and Y-Y of FIGS. 1and 2, the abutment, schematised by the two hatched arrows, of theinternal surfaces of the first corrugated plate and of the second smoothplate immediately before the operation of fixing and sealing of thechannels and the openings.

FIG. 4 b represents the assembly (15) obtained by the abutment of FIG. 4a after the operation of fixing and sealing of the channels and theopenings at the points (16) indicated by the hatched arrows.

FIG. 5 represents the front-view of assembly (15) in which the fixingtracks of the two plates are indicated by reference numeral (17). For acorrect functioning of fuel cells constructed by making use of assembly(15), it is essential that the channels and openings be sealed in orderto prevent gas or coolant leakages between the channels themselves,between openings and between channels and openings: it is thereforenecessary that tracks (17) be continuous as indicated in the figure andfree of defects such as microporosities. Adequate results are achievableby means of the laser welding technique which allows to obtain extremelythin tracks, positioned with high precision by automated equipments ableto guarantee a high reproducibility associated with remarkableproduction speeds. An interesting alternative is represented by asuitable adaptation of the braze welding techniques currently used forthe production of plate exchangers.

The assembly (15) of FIG. 4 b constitutes the basis for the finalmanufacturing step which leads to the bipolar unit of the invention:this stage, schematised in FIG. 6, provides that the first porouscollector (18) be pressed as sketched by the hatches arrows against thesurface of the assembly (15), particularly against the externalcorrugated surface, so as to be interpenetrated in the gaps (19) betweeneach pair of adjacent corrugations forming a single object, especiallycharacterised by the continuity of electrical contact between the wholecorrugated external surface of assembly (15) and the body of thecollector itself. The object thus obtained is finally coupled on theexternal surface thereof, represented by surface (13) of the smoothplate, with the second porous collector (20) secured by welding tracks,optionally discontinuous tracks, or alternatively with adhesive,preferably adhesive of the conductive type, for instance graphite-loadedepoxy cement, applied by spots or alternatively spread as a thin veil onthe whole contact surface. Similar methods may be also applied to thefirst porous collector after pressing in order to better establish thefixing. The overall operation of compression of the first collector andsecuring of the second collector on the assembly (15) allows obtaining afinal monolithic object which constitutes the bipolar unit of theinvention indicated by the reference numeral (21) in FIG. 6. As anoptional alternative it is also possible to interpenetrate the collectorand the corrugations by simultaneously carrying out the pressuremoulding of a planar sheet in contact with a planar collector: the piecethus obtained is subsequently secured to the second plate and theobtained object is secured in its turn to the second collector therebyobtaining the bipolar unit of FIG. 6.

The collectors suitable for forming the bipolar unit of the inventionmust be characterised by electrical conductivity for a good currenttransmission, sufficient porosity to allow an easy flow and ahomogeneous gaseous reactant distribution, and an adequate deformabilityin order to achieve a complete interpenetration with the corrugations ofassembly (15). These requirements are presented by foams, cloths,sintered powders and multilayer packages of thin meshes and expandedsheets, produced with stainless steels of austenitic and ferritic type,nickel-chromium alloys or titanium, also employed as materials for thesolid sheets used in the manufacturing of the corrugated and smoothplates. Such materials are characterised by a good inertia against theaggressiveness of the fluids present inside the fuel cells and theynormally neither give particular problem of deterioration nor a harmfulrelease of poisonous metal ions. In any case, for particularly criticalapplications it is possible to further increase the chemical inertiathrough the application of thin protective conductive layers based onmetals of the group of platinum or oxides thereof, such as for instanceruthenium or ruthenium oxide, optionally added with adhesion promotersselected from the group of niobium, titanium, tantalum and zirconiumoxides. To limit the costs, the protective films have thicknesses as lowas 0.1-1 micrometres: it was found that also with these minimalthicknesses, the films are in any case capable of performing their taskof ensuring a low contact resistance and of highly limiting, if not ofcancelling, the metal ion release, provided their porosity is not higherthan 50%.

The collectors are initially characterised by pores with an averageequivalent diameter preferably comprised between 0.2 and 0.5 mm andthickness of 0.5-5 mm, which is indicatively reduced to 0.2-0.5 mm aftercompression against the corrugated surface of assembly (15).

As indicated in FIG. 7, a pair of bipolar units (21) of FIG. 6 is usedin conjunction with a MEA element to form an elementary fuel cell: theMEA element comprises an ionomer membrane (23), two films (24)consisting of catalyst microparticles and optionally a suitable binder,two gas diffusion layers (25) as known in the art. The MEA element iscompleted by a system of integrated peripheral gaskets (26) directed toseal the various openings in order to prevent gas and coolant leakagesto the external environment and between the openings themselves. In theelementary cell which is formed by abutting the components shown in FIG.7 the channels formed by the corrugations, crossed by the coolant,ensure the optimal control of the operative temperature. The gasreactants flow through the first and the second collector and arehomogeneously distributed to the gas diffusion layers. Such condition isimportant to obtain also a uniform distribution of the electric currenton the catalytic films, but is not sufficient: the uniformity ofdistribution of the electric current, fundamental to obtain the bestvoltage performances and to achieve long operating lifetimes, alsorequires that the electrical contact between bipolar units and MEAelements be uniform and continuous. While in the prior art whereinbipolar units only provided with grooves or corrugations are used theelectrical contact is invariably established between the apexes of thegrooves or corrugations and the MEA elements, and is therefore of thediscontinuous type with a negative repercussion on the electric currentdistribution, the bipolar unit of the present invention ensures acomplete electrical contact uniformity and continuity between both ofthe bipolar unit surfaces, the porous collectors and the MEA elements.

The analysis of FIG. 7 finally demonstrates how the use of MEA elementscomprising membrane, catalytic films, gas diffusion layers and gasketframes in conjunction with the monolithic bipolar units of the inventionleads to stack assembly procedures comprising a multiplicity ofextremely simplified fuel cells, certainly compatible with the low costmass production procedures. Furthermore the stacks consisting of MEAelements and bipolar units according to the invention end up being verycompact as a consequence of the reduced thicknesses characterising theindividual elementary cells, typically comprised between 1 and 2 mm.Such compact stacks are of great interest for all the automotiveapplications, where the weights and particularly the volumes are verycritical.

As it is apparent to one skilled in the art, other changes ormodifications may be introduced to the previous disclosure, that shallnot be intended as a limitation of the invention which may be usedaccording to different embodiments without departing from the scopesthereof and whose extent is univocally defined by the appended claims.

Throughout the description and claims of the present application, theterm “comprise” and variations thereof such as “comprising” and“comprises” are not intended to exclude the presence of other elementsor additives.

1-18. (canceled)
 19. A method of manufacturing a bipolar unit for fuelcells, the bipolar unit comprising a pair of metal plates, each providedwith an external surface and an internal surface, connections betweensaid respective internal surfaces, openings for the transmission ofgaseous reactants and a coolant, at least one of said plates beingprovided with first corrugations forming first channels comprisedbetween said internal surfaces directed to ensure the passage of thecoolant, each of said external surfaces in continuous and uniformelectrical contact with a facing conductive and porous currentcollector, the method comprising formation of said corrugations bypressure molding of a planar sheet.
 20. The method of claim 19 whereinsaid planar sheet has a thickness between 0.05 and 0.2 millimeters. 21.A method of manufacturing a bipolar unit for fuel cells, the bipolarunit comprising a pair of metal plates, each provided with an externalsurface and an internal surface, connections between said respectiveinternal surfaces, openings for the transmission of gaseous reactantsand a coolant, at least one of said plates being provided with firstcorrugations forming first channels comprised between said internalsurfaces directed to ensure the passage of the coolant, each of saidexternal surfaces in continuous and uniform electrical contact with afacing conductive and porous current collector, wherein said continuousand uniform electrical contact between external surface of said at leastone plate provided with first corrugations and said facing porouscollector is given by the interpenetration between said corrugations andsaid collector, the method comprising obtaining said interpenetration bypressure molding of said porous collector on said at least one plateprovided with corrugations.
 22. A method of manufacturing a bipolar unitfor fuel cells, the bipolar unit comprising a pair of metal plates, eachprovided with an external surface and an internal surface, connectionsbetween said respective internal surfaces, openings for the transmissionof gaseous reactants and a coolant, at least one of said plates beingprovided with first corrugations forming first channels comprisedbetween said internal surfaces directed to ensure the passage, of thecoolant, each of said external surfaces in continuous and uniformelectrical contact with a facing conductive and porous currentcollector, wherein said continuous and uniform electrical contactbetween external surface of said at least one plate provided with firstcorrugations and said facing porous collector is given by theinterpenetration between said corrugations and said collector, themethod comprising obtaining said interpenetration by simultaneouspressure molding of a planar sheet and of said porous collector. 23-24.(canceled)